Locking mechanism for miter saw with hinge linkage linear guide

ABSTRACT

A power saw includes a table configured to receive a workpiece, a saw blade and motor assembly, and a linear guide mechanism operatively connected to the table and being configured to pivotally support the saw blade and motor assembly. The linear guide mechanism enables movement of the saw blade and motor assembly along a predetermined linear path in a forward or a rearward direction at a constant level, and includes a first link and a second link pivotally connected by a first hinge connection. The first and second links enable the linear guide mechanism to maintain the saw blade and motor assembly at the constant level. The power saw further includes a locking mechanism which is fixed to the first hinge connection for locking the linear guide mechanism to prevent the saw blade and motor assembly from being moved along the predetermined linear path.

This patent is a continuation-in-part of U.S. Ser. No. 11/284,931 filed Nov. 22, 2005.

BACKGROUND OF THE INVENTION

This patent generally relates to power miter and abrasive cut off saws.

Miter saws have been the subject of continued research and development efforts in the power tool arena for decades, and many improvements have been made that has resulted in increased ease of use and productivity. Artisans who install trim carpentry have used power miter saws for some time and it is well known that wide stock such as crown molding and the like often requires a miter saw with either a bigger saw blade or a configuration that enables the blade to be moved along a horizontal path away and toward the fence of the miter saw. Such blade moving configurations are generally marketed as sliding compound miter saws, principally because most if not all commercially available saws of this type have a sliding guide assembly comprised of elongated rods that slide in respective bushings to move the saw blade and motor assembly relative to the fence of the saw.

Such sliding guide assemblies are an expensive component of such miter saws. The current state of the art for such sliding miter saws includes a linear guide that typically consists of two of such bushings and rod combinations. These relatively expensive linear bearings consist of recirculating ball bearings that operate together with turned, ground, polished and hardened steel rods that are approximately 40 cm long and 30 mm in diameter. To have minimum play and deflection of the saw blade and motor assembly, precise fits are required between the rods and the linear recirculating ball bearings over the entire linear travel of the rods. The rod must be made of a high hardness steel to prevent indentation by the hard steel balls. Such construction is relatively expensive.

Additionally, an undesirable feature of such bushing and rod linear guides is that space must be provided behind the saw for the rods to extend when the saw blade is positioned near the fence. Because of this space requirement, such a sliding saw cannot be put next to a wall which results in a larger footprint being occupied by such a saw. Additionally, these bushings and rod linear guide mechanisms are susceptible to damage from dirt and grit, particularly if the saw is a sliding abrasive cut off saw where an abrasive wheel is used to cut steel and other materials. The abrasive wheel grinds its way through the steel and produces a considerable volume of abrasive particles that generally come out of the back of the saw. These abrasive particles can penetrate into the ball bushings and damage the bearing. While it is possible to cover the rods with a bellows or similar cover, the hostile environment generally leads to degradation of the fabric and penetration of the ball bushing by the abrasive particles.

There is a continuing need for improvement in the design and development of miter and cut-off saws that have linear guide assemblies.

SUMMARY OF THE INVENTION

This patent relates to various embodiments of a power saw having a table configured to receive a workpiece, a saw blade and motor assembly, and a linear guide mechanism operatively connected to the table and being configured to pivotally support the saw blade and motor assembly. The linear guide mechanism enables movement of the saw blade and motor assembly along a predetermined linear path in a forward or a rearward direction at a constant level, and includes a first link and a second link pivotally connected by a first hinge connection. The first and second links enable the linear guide mechanism to maintain the saw blade and motor assembly at the constant level. The power saw further includes a locking mechanism which is fixed to the first hinge connection for locking the linear guide mechanism to prevent the saw blade and motor assembly from being moved along the predetermined linear path.

DESCRIPTION OF THE DRAWINGS

FIG. 1 is a right side perspective view of a first preferred embodiment of the present invention, particularly illustrating the saw blade being located in the extended position away from the fence;

FIG. 2 is a right side perspective view of the embodiment shown in FIG. 1, but illustrating the saw blade in a position near the fence;

FIG. 3 is a side elevation of the embodiment shown in FIG. 1 with the saw blade in the extended position away from the fence;

FIG. 4 is a rear view of the embodiment shown in FIG. 1, with the saw blade away from the fence;

FIG. 5 is a right front perspective view of a second preferred embodiment of the present invention, particularly illustrating the saw blade being located in the extended position away from the fence;

FIG. 6 is a right front perspective view of the embodiment shown in FIG. 5, but illustrating the saw blade in a position near the fence;

FIG. 7 is a side elevation of the embodiment shown in FIG. 5 but illustrating the saw blade in a position near the fence;

FIG. 8 is a rear view of the embodiment shown in FIG. 5, with the saw blade in a position away from the fence;

FIG. 9 is a third preferred embodiment of the present invention, particularly illustrating the saw blade being located in the extended position away from the fence;

FIG. 10 is a side elevation of the embodiment shown in FIG. 9 with the saw blade in the extended position away from the fence.

FIG. 11 is another side elevation of the embodiment shown in FIG. 9, with the saw blade near the fence;

FIG. 12 is a rear view of the embodiment shown in FIG. 9, with the saw blade located away the fence;

FIG. 13 is a perspective view of the right side of a miter saw, with the blade and motor assembly in an extended and lowered position, in accordance with another embodiment of the invention;

FIG. 14 is a perspective view of the right side of the miter saw shown in FIG. 13, with the blade and motor assembly in a retracted and lowered position;

FIG. 15 is a perspective view of the left side of the miter saw shown in FIG. 13, with the blade and motor assembly in an extended position;

FIG. 16 is a perspective view of the left side of the miter saw shown in FIG. 13, with the blade and motor assembly in the retracted and lowered position;

FIG. 17 is a top plan view of the miter saw shown in FIG. 13, with the blade and motor assembly in the retracted and lowered position and the blade being perpendicular to the fence;

FIG. 18 is a top plan view of the miter saw shown if FIG. 13, with the blade and motor assembly in the retracted and lowered position and the blade being at a miter angle to the fence;

FIG. 19 is a is a perspective view of the left side of the miter saw shown in FIG. 13, with the blade and motor assembly beveled to the left side;

FIG. 20 is a sectional view of a locking mechanism in accordance with one embodiment of the invention, shown in a locked position;

FIG. 21 is a sectional view of the locking mechanism shown in FIG. 20 in an unlocked position;

FIG. 22 is top plan view of the locking mechanism of FIG. 20 shown in a locked position when the blade and motor assembly is in a fully retracted position;

FIG. 23 is top plan view of the locking mechanism of FIG. 20 shown in a locked position when the blade and motor assembly is in a fully extended position;

FIG. 24 is a perspective view of the locking mechanism of FIG. 20 shown in an unlocked position when the blade and motor assembly is in a fully retracted position;

FIG. 25 is a perspective view of the locking mechanism of FIG. 20 shown in a locked position when the blade and motor assembly is in a fully retracted position;

FIG. 26 is a perspective view of the locking mechanism of FIG. 20 shown in a locked position when the blade and motor assembly is in a fully extended position; and

FIG. 27 is a perspective view of the locking mechanism of FIG. 20 shown in an locked position when the blade and motor assembly is in a fully extended position.

DETAILED DESCRIPTION

Various different embodiments of the miter saws are shown and described herein, with the each of the embodiments having a multiple hinge linkage that is designated herein as a horizontal hinge linkage that interconnects the saw blade and motor assembly to the table of the miter saw. It should be understood that while it is referred to herein as a generally horizontal hinge linkage, the several shafts of the linkage may not always be exactly horizontal, and may have a pivot axis that can vary up to about 30 degrees in either direction from exact horizontal. However, it is preferred that the axes be in a substantially horizontal orientation when the saw is set at a zero degree bevel position. Regardless of the bevel angle or the orientation of the surface on which the saw is supported, the shafts are preferably substantially parallel to the arbor shaft in which the blade is mounted and therefore substantially perpendicular to the plane of the saw blade.

The horizontal hinge linkage is utilized rather than an elongated rod and bushing configuration and provides increased stiffness to undesired movement of the saw blade arising from structural deflections during cutting operations. Some of the embodiments also have a vertical hinge linkage for maintaining the elevation of the saw pivot head (to which the saw blade and motor assembly is attached) constant during movement of the saw blade and motor assembly away and toward the fence during a cutting operation. One of the described embodiments utilizes the horizontal hinge linkage together with a single rod and bushing arrangement whereby the rod and bushing arrangement also maintains a constant elevation of the saw pivot head as the saw blade and motor assembly is moved toward and away from the fence during a cutting operation. It should be understood that the saw blade and motor assembly is pivotable about a saw pivot that is part of the saw pivot head, which is attached to the horizontal hinge linkage. The saw blade and motor assembly can be pivoted up out of contact with a work piece or moved down into contact with a work piece during a cutting operation as is conventional for miter saws.

Such hinge linkages have a cost advantage compared to conventional bushing and rod guides because they have a simpler construction, which may comprise as few as two generally planar shaped linkages that are connected together by shafts that may preferably incorporate rotary bushings or low cost ball bearings and which are also linked to the support frame of the rotatable table as well as to the saw pivot head. Tight tolerance fits between hinge components are relatively easier to achieve using low cost ball bearings that are preloaded in the axial direction so that nearly all axial and radial play is removed. In contrast, conventional bushings and sliding rod systems require expensive manufacturing processes to ensure that the outside surface of the rod is precise over its entire length. Another advantage of the use of hinge linkages is that their stiffness characteristics are determined primarily from the width of the hinge linkages as measured along the pivot, i.e., shaft axis. Thus, increased system stiffness can be achieved by making the hinge larger and this is generally less expensive than using larger rods and bushings.

As previously mentioned, the horizontal hinge linkage pivots around axes that are perpendicular to the cutting plane of the blade and therefore provides increased stiffness along the axis of rotation of the saw blade and because of this desirable characteristic, the length of the hinge shafts is greater than other shaft lengths such as those used in the vertical hinge linkage. The structural stiffness is very important to the quality of cuts made by the saw. Without the requisite structural stiffness, it is common for the saw blade to deflect out of the desired cutting plane on an intermittent basis which can result in one or more cut discontinuities or jagged cut portions, rather than a continuous smooth cut at the desired angle.

Another advantage of the hinge linkage is that it has greatly reduced sensitivity to dirt and grit because the bearing surfaces of a hinge linkage are not exposed but are contained within a ball bearing or short rotary bushing. Such ball bearing or rotary bushings can be relatively easily sealed compared to a rod and bushing system where the entire rod is a critical bearing surface and therefore has to be sealed with a large accordion or bellow shaped fabric or other type of cover which is often easily damaged.

Turning now to the first preferred embodiment shown in FIGS. 1-4, the miter saw, indicated generally at 10, has a generally circular base 12 with an attached fence 14, which base supports a rotatable table 16 that has a miter arm control assembly, indicated generally at 18, for adjusting the rotational position of the table for setting the miter angle of work piece that would be placed on the table 16. A saw blade and motor assembly, indicated generally at 20, is operatively connected to the table 16 by a linear guide mechanism, indicated generally at 22. The saw blade and motor assembly 20 has an electric motor 24 that is operatively connected through a belt and gear mechanism, not shown but located within housing portion 26 that drives a saw blade 28. A handle 30 enables an operator to move the blade and motor assembly 20 into and out of engagement with a work piece that may be placed on the table 16 adjacent the fence 14. The blade and motor assembly 20 is pivotable about a saw pivot shaft 32 that is connected to a saw pivot head 34 to which the linear guide mechanism 22 is attached. The blade and motor assembly 20 is shown in FIG. 1 to be in a position where the blade is moved to its extended position away from the fence 14 and lowered into cutting position where a workpiece is placed on the table 16. During operation, an operator places a work piece on the table 16, brings the handle 30 down into cutting position either before or after activating the motor 24 and then pushes the handle 30 toward the fence 14 to have the blade 28 cut the workpiece. At the end of the cut, the blade and motor assembly 20 would be essentially in the position shown in FIG. 2 where the bottom reach of the blade 28 is generally coextensive with the fence 14.

The linear guide mechanism 22 of the first preferred embodiment shown in FIGS. 1-4 is designed so that the miter saw has a dual bevel operation, rather than a single bevel operation, meaning that the bevel angle can be adjusted either right or left from the normal zero angle or position wherein the plane of the blade 28 is perpendicular to the plane of the top surface of the table 16. The blade and motor assembly 20 as well as the linear guide mechanism and rotate about a bevel pivot shaft 36, with the linear guide mechanism having a support frame 38 with a generally cylindrical end portion 40 to which the bevel pivot shaft 36 is connected to. The shaft 36 extends through an opening in an enlarged extension 42 of the table 16. Thus, the end portion 40 can rotate relative to the extension 42 and be supported by the shaft 36. The support frame 38 is preferably a casting that has a lower flange 44, an upper flange 46 as well as vertically oriented flanges 48 and 50.

A horizontal hinge linkage is comprised of links 52 and 54 which have adjacent ends connected together by a shaft 56. The saw pivot head 34 has a pair of spaced flanges 58 as well as a single flange 60 located below the flanges 58. The link 54 has its opposite end connected to the flanges 58 by a shaft 62. Similarly, the opposite end of the link 52 is connected to the vertical flanges 48 and 50 by a shaft 64. As previously mentioned and while not specifically illustrated, the shafts 32, 62, 56, 64, 78 and 82 are preferably of the type which utilize rotary bushings or low cost ball bearings so that they are freely rotatable and will have an extended useful life.

As is best shown in FIGS. 1 and 2, the link 52 has a generally L-shaped side configuration with the transverse extension 66 having the aperture in which the shaft 56 is located. This permits the two links 52 and 54 to be folded together in a generally parallel arrangement as shown in FIG. 2 when the blade and motor assembly 20 is moved into its final cutting position where the blade is adjacent to the fence 14. As is best shown in FIG. 4, the width of the links 52 and 54 is relatively large and therefore the shafts 56, 62 and 64 that interconnect the links 52 and 54 with one another and with the saw pivot head 34 and support frame 38 are relatively long. This contributes to the desirable stiffness of the linear guide mechanism which substantially reduces, if not eliminates, any movement by the blade out of the cutting plane which can result in poor quality cutting. Stated in other words, the extremely wide links and their coupling to the saw pivot head and support frame 38 results in high rigidity reducing torsional and linear deflection of the saw blade away from its intended cutting plane which is very desirable from a cut quality standpoint.

As best shown in FIG. 4, the link 52 is not a solid construction, but has side walls 68 and end walls 70 with cross braces 72 provided to provide increased overall strength for the link. The link 54 is similarly constructed as is shown in FIG. 1, it also having similarly configured side walls, end walls and cross braces. The hinge links 52 and 54 are preferably die cast aluminum but can be steel stamping if desired.

The vertical hinge linkage is located below the horizontal hinge linkage and it comprises links 74 and 76 which have adjacent ends connected together by a vertical shaft 78. The links 74 and 76 are not as wide as the horizontal hinge links 52 and 54 for the reason that their functionality is to maintain the elevation of the saw pivot head 34 constant during movement of the blade and motor assembly 20 toward and away from the fence 14. Elevational deflections are not as critical for a miter saw cut quality for the reason that the work piece is generally being completely cut through.

The narrower links 74 and 76 are vertically displaced from one another which requires the elongated vertical shaft 78 to extend to interconnect them. The link 74 is located between the horizontal flanges 44 and 46 and is pivotally connected to these flanges by a shaft 80. Similarly, the link 76 has spaced flange portions that are connected to the flange 60 by a shaft 82. As is shown in FIG. 1, the flange 60 is located beneath the near flange 58 and the flanges 44 and 46 are also located beneath the vertical flanges 48 and 50, and the shaft 78 that interconnects the links 74 and 76 extends away or to the left side of the saw (as viewed from the handle 30) so that when the vertical and horizontal linkages are folded together as shown in FIG. 2, little if any portion of the links extend outside of the width of the flanges 48 and 50. This is significant in that changing of the bevel angle of the blade and motor assembly 20 can be accomplished in either the left or the right direction and the hinge linkages will not interfere with the dual bevel adjusting capability.

It should also be apparent from FIG. 2 that when the blade and motor assembly 20 are moved as far toward the fence 14 as is possible, the linkages do not extend in any rearward direction beyond the original position end of the support frame 38. This enables the miter saw to be placed near a wall, for example, and be fully operational, unlike many conventional sliding rod and bushing configurations of compound miter saws.

A second preferred embodiment is shown in FIGS. 5-8 and have many similar components as the embodiment shown in FIGS. 1-4. In the following description, components that are labeled with the same numbers as those shown and described with regard to the first preferred embodiment are substantially similar in their design, configuration and operation and therefore will not be described in detail. Components with reference numbers having a prime or double prime designation are similar to those that are identified with regard to the embodiment shown in FIGS. 1-4, but may have some structural differences which are apparent or which will be generally described or which will be given different numbers than those illustrated in FIGS. 1-4.

The second preferred embodiment is indicated generally at 100 in FIGS. 5-8 and has many similarities to the first preferred embodiment, but while the first embodiment is a dual bevel configuration saw, the second embodiment saw 100 is a single bevel configuration. The links 74′ and 76′ are connected together by a shaft 78′ that is not as long as the shaft 78 of the first preferred embodiment, because the links 74′ and 76′ are vertically adjacent one another rather than being spaced apart. Also, the link 76′ is at an elevation that is substantially similar to the elevation of the link 54′ and therefore unable to fold toward the link 52″ and 54′. Thus, the connection between link 74′ and 76′ extends outwardly away from the links 52′ and 54′. Because of the outward extension, particularly when it is folded as shown in FIGS. 6 and 8, the links interfere with other portions of the saw 100 when the saw would be pivoted in the counterclockwise direction as shown in FIG. 8. Therefore, the single bevel operation of this second preferred embodiment is in the clockwise direction as shown in FIG. 8.

A third preferred embodiment of the invention is the saw 110 that is shown in FIGS. 9-12 is less detail than the embodiments of FIGS. 1-8. Saw 110 has a horizontal hinge linkage comprising links 52″ and 54″ that are interconnected and operate substantially similar to those described in the embodiments of FIGS. 1-8. The saw pivot head 34″ has a slightly different configuration and the end of the link 54″ is connected to the saw pivot shaft 32 which is also journaled in the saw pivot head 34″. An elongated rod 112 is journaled in a bushing (not shown but located in the upper end of support frame 38) and maintains the saw pivot head 34″ at a constant elevation as the blade and motor assembly 22 moves the blade 28 toward the fence 14. Only one rod 112 is provided for the reason that control of the saw blade cutting plane is provided by the horizontal hinge linkage, as is the case with the other embodiments shown in FIGS. 1-8, and the only function that is performed by the rod 112 is to keep the pivot head 34″ at a constant elevation during operation. In this regard, the blade and motor assembly 20 is shown in its retracted position in FIGS. 9 and 10 and in the cutting position in FIG. 11 where the blade 28 is adjacent the fence 14. In the position shown in FIG. 11, it is apparent that the rod 112 will extend beyond the rear surface of the support frame 38″ which requires a larger footprint in that it would not be possible to place the saw 110 with the support frame 38″ located close to a wall or other similar surface. Thus, while this embodiment does not have the space advantages of the first and second preferred embodiments, this embodiment has the advantage of controlling the saw blade cutting plane by a generally horizontal hinge as is achieved in all embodiments and only one rod and bushing combination is required which provides a cost benefit compared to conventional arrangements which have a pair of rod and bushing configurations.

In accordance with another embodiment of the invention, a miter saw is shown in FIGS. 13-19 and is indicated generally at 200. This embodiment is also described in related U.S. application Ser. No. ______ (GBC Docket No. 0212.072978C1), which is hereby incorporated by reference it its entirety. Many of the components are similar to the first embodiment 10 so that where reference numbers are the same as the description of the FIG. 1, such components and their functionality are very similar, if not identical. Components with reference numbers above 200 are sufficiently different from analogous components of the other embodiments to warrant separate numbers or are new in the fourth embodiment.

Turning to FIGS. 13 and 14, a miter saw 200 also has a generally circular base 12 with an attached fence 14. The base 12 supports a rotatable table 16 that has a miter arm control assembly, indicated generally at 18, for adjusting the rotational position of the table for setting the miter angle of a workpiece that would be placed on the table. A saw blade and motor assembly, indicated generally at 20, is operatively connected to the table 16 by a linear guide mechanism, indicated generally at 202. The saw blade and motor assembly 20 has an electric motor 24 that is operably connected through a belt and gear mechanism (not shown), but located within the housing portion 26 that drives a saw blade 28. A handle 30 enables the operator to move the blade and motor assembly 20 into and out of engagement with a workpiece (not shown) that is placed on the table 16 adjacent the fence 14.

The blade and motor assembly 20 is pivotable about a saw pivot connection shaft 204 extending between a pair of spaced outer flanges 206 on a pivot head 208. When the handle 30 is lowered by an operator, the blade 28 will be lowered into its cutting position and slightly penetrates a slot 210 formed in the table 16. The pivot head 208 also has a pair of spaced inner flanges 212 (best shown in FIG. 13) that extend in the opposite direction from the outer flanges 206 that are connected to the blade and motor assembly 20, and offset from the center of the pivot head 208, opposite one of the outer flanges 206. The inner flanges 212 are provided between a pair of spaced outer flanges 218 extending from one end of a first horizontal link 214. A pivot connection shaft 216 extends horizontally through holes in the inner and outer flanges 212 and 218 to pivotally connect the inner and the outer flanges 212, 218. Together the inner flanges 212 of the pivot head 208, the pivot connection shaft 216 and the outer flanges 218 of the first horizontal link 214 form a horizontal hinge connection 220.

At the opposite end from the horizontal hinge connection 220, the first horizontal link 214 is connected to a slightly longer second horizontal link 222 by another horizontal hinge connection 224. It should be understood, however, that the miter saw 200 may include one or more additional horizontal links that may be connected to the first and second links 214, 222 without departing from the scope of the patent. Included in the hinge connection 224 is a pair of spaced inner flanges 226 that extend from the end of the first horizontal link 214 opposite the end having outer flanges 218. The inner flanges 226 are provided between and pivotally connected to a pair of spaced outer flanges 228 extending from the upper end portion of the second horizontal link 222, by a pivot connection shaft 230.

The second horizontal link 222 has its lower end portion connected to a vertical support 232 by a horizontal hinge connection 234. The hinge connection 234 includes a pair of spaced outer flanges 236 (best shown in FIG. 15) extending from the top of the vertical support 232 and a pair of inner flanges (not shown) extending from the lower end of the horizontal link 222 and provided between the outer flanges of the vertical support. A pivot connection shaft 238 extends through the outer flanges 236 of the vertical support 232 and the inner flanges of the second horizontal link 222 for a pivotal connection. The outer flanges 228 of the second horizontal link 222 in the hinge connection 224 extends at an angle of approximately 30 degrees from the generally linear longitudinal portion of the second horizontal link to enable the first horizontal link 214 to be folded close to the second horizontal link, as shown in FIG. 14. It is to be understood that the angle other than the described above may be utilized as well.

As is best shown in FIGS. 14 and 16, when the blade and motor assembly 20 is in its retracted position, the second horizontal link 222 is in a generally vertical orientation. It should be appreciated that the horizontal pivot connection shafts 216, 230, 238, and the corresponding hinge connections 220, 224, 234, are oriented parallel to one another and substantially perpendicular to the plane of the blade 28. The first and second horizontal links 214, 222 are relatively wide, approximately 80 to 160 millimeters and the thickness of them is substantial, approximately 10 to 80 millimeters so that they resist bending which would detrimentally affect the quality of the cut by the blade 28. The length of the first horizontal link 214 is approximately ¾ of the length of the second horizontal link 222. In one embodiment, the length of the first horizontal link 214 is approximately 120 to 220 millimeters and that of the second horizontal link 222 is approximately 200 to 300 millimeters so that the point of the blade 28 that make contact with the workpiece is at a sufficient distance from the fence 14 to cut the intended workpiece, but before the contact point reaches the end of the slot 210 provided in the table 210. Of course, it should be understood that the width, the thickness, and the length of the first and second links 214, 222 other than those described above may be utilized as well.

The vertical support 232 is integrally formed with a support frame 240 that is generally cylindrically shaped. Of course, the support frame 240 may take the form of various shapes and have a number different sizes. A bevel pivot shaft 242 supported by an extension 244 of the table 16 enables the support frame 240 and the vertical support 232 to pivot either to the left or right of the plane of the blade 28 for the purpose of providing bevel cuts. The vertical support 232 also has a side mounting structure 246 with a pivot block 248 for pivotally supporting an angled first vertical link 250, which has a pair of outer flanges 252 at one end. The pivot block 248 is provided between and connected to the two outer flanges 252 of the first vertical link 250 by a vertical pivot connection shaft 254 that extends through the holes formed in the outer flanges and the pivot block. The outer flanges 252, the pivot block 248 and the pivot connection shaft 254 combine to form a vertical hinge connection 256. It should be noted that the pivot block 248 can be an integral part of the vertical support 232, or it can be a separate component that is affixed to the vertical support 232.

Referring to FIGS. 13, 15 and 16, the first vertical link 250 has a pair of spaced inner flanges 258 extending from the end opposite the end having the outer flanges 252. The inner flanges 258 are provided between a pair of spaced outer flanges 260 extending from a second vertical link 262. A vertical pivot connection shaft 264 extends through the aligned holes in the inner and outer flanges 258, 260 to pivotally connect the first and second vertical links 250, 260 together and form a vertical hinge connection 266. While the inner flanges 258 are described as being “spaced,” it should be understood that they are not necessarily separated. They can also be integrally connected by a somewhat narrower piece provided between the flanges 258. Alternatively, the inner flanges 258 can also be replaced with one cylindrical piece protruding from the end of the link 250.

As best shown in FIG. 15, the outer and the inner flanges 260, 258 of the second vertical link 262 and the first vertical link 250 extend at a slight angle from the linear portion of each of the first and second vertical links 250,262 to enable the first and second vertical links 250, 262 to be folded close to each other, as shown in FIG. 16. Preferably, the flanges 258, 260 should extend at an angle of approximately 30 to 120 degrees relative to the linear portion of the respective first and second vertical links. It is to be understood that the angle other than the described above may be utilized as well.

At the opposite end from the outer flanges 260, a pair of spaced outer flanges 268 extend from the second vertical link 262 and are pivotally connected to a pivot block 270 provided between the two outer flanges by a vertically oriented pivot connection shaft 272 (best shown in FIGS. 13 and 14), thereby forming another vertical hinge connection 274. The pivot block 270 is attached to the pivot head 208 on the opposite side from the outer flanges 206 and adjacent the inner flanges 212 of the pivot head.

As with the embodiment shown in FIG. 13, the vertical pivot connection shafts 254, 264, 272 maintain the elevation of the pivot head 206 substantially constant relative to the table 16. The length of the first vertical link 250 is approximately the same as the length of the second vertical link 262, and each of the first and second vertical links 250, 262 are approximately 7/10 of the length of the second horizontal link 222. In one embodiment, the length of the first vertical link 250 is approximately 120 to 220 millimeters and that of the second vertical link 262 is also approximately 120 to 220 millimeters. The width and thickness of the first and second vertical links 250, 262 are comparable to the first and second horizontal links 214, 222. However, the amount of possible bending of the vertical links 250, 262 is not as critical as bending that could occur with the horizontal links 214, 222 inasmuch as the quality of a cut is generally not affected by vertical movement of the blade during extension and retraction because the blade penetrates the slot 210 during most cutting operations. Of course, it is to be understood that the width, the thickness, and the length of the first and second links 214, 222 other than those described above may be utilized as well. As is evident from the drawings, the horizontal and vertical links 214, 222, 250, 262 are not solid but may be constructed from cast of aluminum and have reinforcing ribs 276 (best shown in FIG. 14) that extend across the interior of the links to impart additional strength. In some embodiments, the horizontal and vertical links 214, 222, 250, 262 may be constructed from steel stamping, sheet metal, or any high strength plastic.

Additional structural strength is provided in this embodiment for the reason that all the horizontal and the vertical hinge connections 220 224, 234, 256, 266, 274 have outer flanges that fit outside a pair of inner flanges or pivot blocks, which support each the horizontal and vertical links 214, 222, 250, 262 at both ends rather than an overhung load connection. The double-ended support provides a stronger connection that imparts an increased strength to the links. The horizontal and vertical pivot connection shafts 216, 230, 238, 254, 264, 272 are, therefore, also supported at opposite ends, which is a stronger connection.

In the described fourth embodiment, the vertical hinge connection 256 at the lower end of the first vertical link 250 is provided at the top portion of the vertical support 232 (not including the outer flanges 236) and is slightly below the vertical hinge connection 266 at the other end of the vertical link 250 (best shown in FIG. 14). Accordingly, the vertical link 250 extends at an angle between the vertical hinge connections 256 and 266. It should be understood, however, that the length of the vertical support 232 may be increased so that the location of the pivot block 248, and accordingly, the vertical hinge connection 256, may be at the same height as the vertical hinge connection 266. In other words, the first vertical link 250 may extend substantially parallel to the table top 16 as is the second vertical link 262. However, with this arrangement, there may be an issue of the miter saw 200 being undesirably top heavy.

Another consideration is that the angle between the first and second horizontal links 214, 222 as determined by the line of action between a line extending through pivot connection shafts 230 and 216 in the horizontal hinge connections 224 and 220 relative to the line of action through pivot connection shafts 230 and 238 in the horizontal hinge connections 224 and 234, identified as angle θ₁ in FIG. 15 should be less than 130° when the saw is fully extended to prevent a toggle action of the links. While not shown, the angle between the first and second vertical links 250 and 262 as determined by the line of action between a line extending through vertically oriented pivot connection shafts 264 and 254 in the vertical hinge connections 266 and 256 relative to the line of action through vertical pivot connection shafts 264 and 272 in the vertical hinge connections 266 and 274, also should be less than 130° when the saw is fully extended to prevent a toggle action of the links. The toggle action is defined herein to mean an increased necessary force to push the blade and motor assembly 20 from its extended position, shown in FIGS. 13 and 15 toward the retracted position shown in FIGS. 14 and 16. If a toggle action is experienced, a greater noticeable and appreciable force is required to start the movement. If the angles of the links are less than 130°, such toggle action is not experienced.

During operation, an operator places a workpiece on the table 16, brings the handle 30 down into cutting position either before or after activating the motor 24, as shown in FIGS. 13 and 15, and then pushes the handle 30 toward the fence 14 to have the blade 28 cut the workpiece. At the end of the cut, the blade and motor assembly 20 would be essentially in the position shown in FIGS. 14 and 16, where the bottom reach of the blade 28 is generally coextensive with the fence 14.

As is shown in FIGS. 15 and 16, the first and second vertical links 250, 262 are located beneath the first and second horizontal links 214, 222 and the vertical connection hinge 266 that interconnects the vertical links extends away or to the left side of the saw (as viewed from the handle 30). In this manner, when the saw 200 is in a retracted position and the vertical and horizontal links 214, 222, 250, 262 are folded together, as shown in FIGS. 16-19 only a small portion (e.g., approximately 20 to 100 millimeters) of the vertical links 250, 262 extend outside of the width of the horizontal links 214, 222. This is significant in that changing of the bevel angle of the blade and motor assembly 20 can be accomplished in either the left or right direction and the vertical links 250, 262 will not interfere with the dual bevel adjusting capability, as illustrated in FIG. 19.

Another desirable attribute of this described embodiment is particularly illustrated in FIGS. 14, 16 and 17 wherein the blade and motor assembly 20 is in its retracted position and the second horizontal link 214 is substantially vertical. Since the link 214 does not extend rearwardly beyond the vertical support 232, it can be appreciated that the saw 200 can be placed very close to a rear wall or the like without impairing the normal operation of the saw.

In accordance with another aspect of the invention, the miter saw 200 includes a locking mechanism, indicated generally at 278, for locking the saw blade and motor assembly 20 in a fully retracted position (see FIG. 16) or a fully extended position (see FIG. 15). During transport, the blade and motor assembly 20 may undesirably move from one position to another which can make the saw more cumbersome, or even hazardous, to carry. The locking mechanism 278 locks the saw blade and motor assembly 20 in the fully extended position so that the saw 200 is easier to carry. Also, when making chop cuts where the blade 28 is brought down onto the workpiece without sliding the saw blade and motor assembly 20 to an extended position, the locking mechanism 278 locks the saw blade and motor assembly 20 in the fully retracted position.

Referring to FIGS. 20 and 21, the locking mechanism 278 includes pivot foot 280, a generally flat, horizontally oriented locking lever 282 extending from the foot in one direction, and a generally flat, vertically oriented wedge 284 extending from the foot in the opposite direction of the locking lever. The foot 280 is pivotally connected to a pair of spaced support arms 286 which protrude from the top one of the inner flanges 258 on the first vertical link 250 by a pin 288 (best shown in FIGS. 24 and 25). The pin 288 extends through a hole in each of the arms 286 and an aligned hole formed in the foot 280. The pin 288 is secured in the hole by any know means such as a threaded nut or a retaining ring, for example.

The locking mechanism 278 also includes a generally flat spring 290 (best shown in FIGS. 20, 21, 25 and 26), one end of which is fixed to the flange 258 between the two support arms 286. The spring can be attached to the flange 258 by welding, screws or otherwise affixed to the flange in any known manner. The spring 290 can also be secured by wrapping the end around the pin 288. The spring 290 is configured to be curved upwardly to a U shape as shown in FIGS. 20 and 21. Preferably, the spring 290 is made of metal so that it biases against force pressing on it and has the resiliency to go back to its predefined shape. However, plastic or other suitable material with sufficient resiliency may also be utilized for the spring 290.

The spring 290 serves to maintain the locking mechanism 278 in its current position, whether in a locked position, as shown in FIG. 20 or in an unlocked position, as shown in FIG. 21. When in the locked position, the spring 290 biases against a lip 292 protruding from the foot 280 to urge the lever 282 and the wedge 284 or in a clockwise direction to a horizontal position. In this position, the wedge 284 is placed in an elongated locking slot 294 created between the top inner flange 258 of the first vertical link 250 and the top outer flange 260 of the second vertical link 262 (best shown in FIGS. 24 and 27). In the unlocked position, the spring 290 is biased against the front of the foot 280 between the lip 292 and the locking lever 282 to maintain the lever 284 and the wedge 284 in an angled position, so that the wedge 284 is kept out of the locking slot 294. The locked and unlocked positions can be at both the fully retracted position (FIGS. 25 and 24, respectively) and in the fully extended position (FIGS. 26 and 27, respectively).

The flanges 258 extend from the end of the first vertical link 250, thereby defining a pair of shoulders 296 with a flat surface 298 (best shown in FIG. 21). The surface 298 is at an angle of approximately 150 degrees relative to the straight longitudinal section of the first vertical link 250 extending between the hinge connections 266 and 248 (best shown in FIG. 22). As shown in FIG. 22, the outer flanges 260 of the second vertical link 262 each has a flat inside surface 300 facing and spaced from the shoulder surfaces 298 of the vertical link 250. When the blade and motor assembly 20 is moved to the fully retracted position, the opposing shoulder surface 298 and the inside surface 300 of the second vertical links 262 are spaced parallel to each other and define the locking slot 294. Accordingly, the outer flanges 260 extend at an approximately 150 degree angle relative to the straight longitudinal section of the second vertical link 250 extending between the hinge connections 266 and 274, so that the inside surface 300 is parallel to the shoulder surface 298 of the first vertical link 250.

The outer flanges 260 also have a generally flat end surface 302 which extends away from the inside surface 300 at an angle slightly less than 90 degree. When the blade and motor assembly 20 is moved to the fully extended position, the end surface 302 of the outer flanges 260 and the opposing shoulder surface 298 are spaced parallel to each other and define the locking slot 294, as shown FIG. 23.

As shown in FIGS. 22 and 23, in the locked position, the wedge 284 displaces almost the entire space within the locking slot 294. As a result, the outer flanges 260 of the second vertical link 262 and the inner flanges 258 of the first vertical link 250 are prevented from pivoting relative to each other. In other words, the locking mechanism 278 makes the vertical hinge connection 266 connecting the first and second vertical links 260, 262 inoperable. Moreover, the locking mechanism 278 can be put into the locking position only from the fully extended or fully retracted positions. At any place in between these two positions, the locking slot 294 does not have the opposing surfaces 298 and 302 that are parallel, and therefore, the locking slot 294 would be too narrow and incapable of receiving the wedge 284.

In operation, to lock the blade and motor assembly 20, the user moves the blade and motor assembly to either the fully retracted position (FIG. 23) or the fully extended position (FIG. 26), so that the locking slot 294 is formed between the opposing shoulder surface 298 of the first vertical link 250 and the inside surface 302 of the outer flanges (if fully retracted) or between the shoulder surface 298 and the end surface 302 of the outer flanges 260 (if fully extended). The locking lever 282 is then lifted upwardly to cause the foot 280 to pivot about the pin 288 and bring the wedge 284 into the locking slot 294 (see FIG. 20). The wedge 284 is maintained in the locking slot 294 by the tension on the free end of the spring 290 acting against the lip 292 in a clockwise direction.

To unlock the blade and motor assembly 20, the user pushes the locking lever 282 downwardly to overcome the force acting on the lip 292 of the foot 280 and causes the foot to pivot counterclockwise about the pin 288 and bring the wedge 284 completely out of the locking slot 294 (see FIG. 21). In the unlocked position, the free end of the spring 290 is positioned on the front of the foot 280, between the lip 292 and the locking lever 282. The force of the spring acting on the front of the foot 280 keeps the locking mechanism 278 in the unlocked position, so that the user is able to slide the blade and motor assembly 20 as desired.

While various embodiments of the invention have been shown and described, it should be understood that other modifications, substitutions and alternatives are apparent to one of ordinary skill in the art. Such modifications, substitutions and alternatives can be made without departing from the spirit and scope of the invention, which should be determined from the appended claims. Various features of the invention are set forth in the following claims. 

1. A power saw comprising: a table configured to receive a workpiece; a saw blade and motor assembly; a linear guide mechanism operatively connected to said table and being configured to pivotally support said saw blade and motor assembly, said linear guide mechanism enabling movement of said saw blade and motor assembly along a predetermined linear path in a forward or a rearward direction at a constant level; said linear guide mechanism including a first link and a second link pivotally connected by a first hinge connection, said first and second links enabling said linear guide mechanism to maintain said saw blade and motor assembly at said constant level; and a locking mechanism fixed to said first hinge connection for locking said linear guide mechanism to prevent said saw blade and motor assembly from being moved along said predetermined linear path.
 2. The power saw as defined in claim 1, wherein said locking mechanism locks said linear guide mechanism in a retracted position in said rearward direction or in an extended position in said forward direction.
 3. The power saw as defined in claim 1, wherein said locking mechanism includes an elongated wedge portion configured to be pivotally inserted in a space created between opposing ends of said first and second links at said first hinge connection, to prevent said first and second links from pivoting about said first hinge connection relative to each other.
 4. The power saw as defined in claim 3, wherein said locking mechanism further includes a pivot foot from which said wedge portion extends, and a locking lever extending from said pivot foot for operatively pivoting said wedge portion about said pivot foot to insert or extract said wedge portion in and from said space between said opposing ends of said first and second links.
 5. The power saw as defined in claim 4, wherein said locking mechanism further includes a spring member for biasing said pivot foot at a first position to retain said wedge portion in said space between said opposing ends of said first and second links, or at a second position to maintain said wedge portion outside of said space.
 6. The power saw as defined in claim 5, wherein said pivot foot has a lip protruding at said first position and said spring member biases against an end of said lip to retain said wedge portion in said space between said opposing ends of said first and second links, and said second position is provided between said lip and said locking lever.
 7. The power saw as defined in claim 4, wherein said pivot foot pivots about a pin supported between a pair of spaced arms protruding from said first hinge connection.
 8. The power saw as defined in claim 3, wherein said space between said opposing ends of said first and second links is configured to receive said wedge portion at least one predefined angle between said first and said second links.
 9. The power saw as defined in claim 8, wherein said opposing ends of said first and second links are angled such that a shape of said space corresponds to a shape of said wedge portion at said at least one predefined angle between said first and said second links.
 10. The power saw as defined in claim 9, wherein said shape of said space corresponds to said shape of said wedge portion at said at least two predefined angles between said first and said second links.
 11. A locking mechanism in a power saw for locking a linear guide mechanism that supports a saw blade and motor assembly and enables movement of said saw blade and motor assembly along a predetermined linear path in a forward or a rearward direction at a constant level, said locking mechanism comprising: a pivot foot pivotally attached to a first hinge connection connecting a first link and a second link of said linear guide mechanism, said first and said second links enabling said linear guide mechanism to maintain said saw blade and motor assembly at a constant level; an elongated wedge portion extending from said pivot foot and configured to be pivotally inserted in a space created between opposing ends of said first and second links; and a locking lever extending from said pivot foot for operatively pivoting said wedge portion about said pivot foot to insert or extract said wedge portion in and from said space between said opposing ends of said first and second links; wherein said wedge portion prevents said first and second links from pivoting about said first hinge connection relative to each other when said wedge portion is inserted in said space between said opposing ends of said first and second links.
 12. The locking mechanism as defined in claim 11, further comprising a spring member for biasing said pivot foot at a first position to retain said wedge portion in said space between said opposing ends of said first and second links, or at a second position to maintain said wedge portion outside of said space.
 13. The locking mechanism as defined in claim 12, wherein said pivot foot has a lip protruding at said first position and said spring member biases against an end of said lip to retain said wedge portion in said space between said opposing ends of said first and second links, and said second position is provided between said lip and said locking lever.
 14. The locking mechanism as defined in claim 11, wherein said pivot foot pivots about a pin supported between a pair of spaced arms protruding from said first hinge connection.
 15. The power saw as defined in claim 11, wherein said space between said opposing ends of said first and second links is configured to receive said wedge portion at least one predefined angle between said first and said second links.
 16. The power saw as defined in claim 15, wherein said opposing ends of said first and second links are angled such that a shape of said space corresponds to a shape of said wedge portion at said at least one predefined angle between said first and said second links.
 17. A power miter saw having a locking mechanism, comprising: a rotatable table configured to receive a workpiece; a pivotable saw blade and motor assembly including a motor for rotating a circular saw blade; a linear guide mechanism operatively connected to said table and being configured to pivotally support said saw blade and motor assembly, said linear guide mechanism enabling movement of said saw blade and motor assembly along a predetermined linear path in a forward or a rearward direction at a constant level; said linear guide mechanism including a first link and a second link pivotally connected by a first hinge connection, said first and second links enabling said linear guide mechanism to maintain said saw blade and motor assembly at said constant level; a pivot foot pivotally attached to a first hinge connection pivotally connecting a first link and a second link of said linear guide mechanism, said first and second links enabling said linear guide mechanism to maintain said saw blade and motor assembly at a constant level; an elongated wedge portion extending from said pivot foot and configured to be pivotally inserted in a space created between opposing ends of said first and second links; and a locking lever extending from said pivot foot for operatively pivoting said wedge portion about said pivot foot to insert or extract said wedge portion in and from said space between said opposing ends of said first and second links; wherein said wedge portion prevents said first and second links from pivoting about said first hinge connection relative to each other when said wedge portion is inserted in said space between said opposing ends of said first and second links.
 18. The locking mechanism as defined in claim 17, further comprising a spring member for biasing said pivot foot at a first position to retain said wedge portion in said space between said opposing ends of said first and second links, or at a second position to maintain said wedge portion out of said space.
 19. The power saw as defined in claim 17, wherein said opposing ends of said first and second links are angled such that a shape of said space corresponds to a shape of said wedge portion at least one predefined angle between said first and said second links.
 20. The power saw as defined in claim 19, wherein said shape of said space corresponds to said shape of said wedge portion at a first predefined angle near an end of said forward direction movement of said saw blade and motor assembly, and at a second predefined angle near an end of said rearward direction movement of said saw blade and motor assembly. 